Vehicle seat assembly with side-impact airbag deployment mechanism

ABSTRACT

A vehicle seatback assembly includes an outer shell coupled to a seatback carrier via a releasable coupling arrangement. The releasable coupling arrangement can take various forms in order to securely couple the outer shell to the seatback carrier. A seatback frame is disposed between the seatback carrier and the outer shell in assembly. An airbag module is coupled to the seatback frame, and the releasable coupling arrangement is configured to release upon deployment of an airbag from the airbag module to define a peripheral gap between the outer shell and seatback carrier through which the airbag can be deployed.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent application Ser. No. 14/635,025, filed Mar. 2, 2015, and entitled VEHICLE SEAT ASSEMBLY WITH SIDE-IMPACT AIRBAG DEPLOYMENT MECHANISM, the entire disclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to a vehicle seat assembly, and more particularly, to a vehicle seat assembly having modular components which are coupled together in such a way as to allow for effective deployment of a side-impact airbag device.

BACKGROUND OF THE INVENTION

Vehicle seat assemblies are currently provided having integrated safety features for the protection of the vehicle occupant. Vehicle seat assemblies must be constructed in such a way that the vehicle seat is structurally sound and provides the support necessary for a vehicle occupant. In order to improve the safety features of a vehicle seat, an airbag deployment device may be incorporated into the vehicle seat design. When an airbag deployment device is integrated into the vehicle seat design, the assembly of the vehicle seat must accommodate proper deployment of the airbag deployment device. Thus, it is desirable to provide a seat assembly that can be assembled in an efficient manner while providing coupling features that are configured to allow for proper deployment of an airbag deployment device.

SUMMARY OF THE INVENTION

One aspect of the present invention includes a vehicle seatback assembly having a rear seatback module defined by an outer shell, wherein the outer shell includes first and second side members. One or more mounting features are disposed on one of the first and second side members of the outer shell. A seatback carrier includes first and second side members, which are configured to align with the first and second side members of the outer shell in assembly. One or more mounting members are disposed on one of the first and second side members of the seatback carrier. In assembly, the one or more mounting features disposed on the outer shell are configured to align with the one or more mounting members disposed on the seatback carrier. A releasable coupling arrangement is defined between the one or more mounting features disposed on the outer shell and the one or more mounting members disposed on the seatback carrier. An airbag module is coupled to a seatback frame disposed between the seatback carrier and the outer shell. The releasable coupling arrangement is configured to release upon deployment of the airbag module to disengage a portion of the outer shell from the seatback carrier along a mating joint formed therebetween.

Another aspect of the present invention includes a vehicle seatback assembly having an outer shell releasably engaged with a seatback carrier via a coupling arrangement to define a mating joint therebetween. A seatback frame is disposed between the seatback carrier and the outer shell. An airbag module is coupled to the seatback frame and the coupling arrangement is configured to release upon deployment of the airbag module to disengage a portion of the outer shell from the seatback carrier along the mating joint.

Yet another aspect of the present invention includes a vehicle seatback assembly having an outer shell coupled to a seatback carrier via a releasable coupling arrangement. A seatback frame is disposed between the seatback carrier and the outer shell in assembly. An airbag module is coupled to the seatback frame, and the releasable coupling arrangement is configured to release upon deployment of an airbag from the airbag module to define a peripheral gap between the outer shell and seatback carrier through which the airbag can be deployed.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a vehicle seat assembly according to one embodiment of the present disclosure;

FIG. 2 is a perspective view of a seatback carrier of a vehicle seat;

FIG. 3A is an exploded perspective view of a front seatback module including the seatback carrier of FIG. 2;

FIG. 3B is a perspective view of the front seatback module of FIG. 3A as assembled;

FIG. 4 is a perspective exploded view of the front seatback module of FIG. 3B, a rear seatback module, and a headrest module exploded away from a seatback frame;

FIG. 5 is a perspective view of the seatback carrier of FIG. 2 coupled to the seatback frame and rear seatback module of FIG. 4;

FIG. 6A is a fragmentary cross-sectional view taken at line VIA of FIG. 5, showing a coupling arrangement between the seatback carrier and rear seatback module according to one embodiment;

FIG. 6B is a cross-sectional top plan view of the coupling arrangement shown in FIG. 6A including an airbag module;

FIG. 6C is a cross-sectional top plan view of the coupling arrangement shown in FIG. 6B, showing an airbag in a deployed condition;

FIG. 7A is a fragmentary cross-sectional view taken at line VIA of FIG. 5, showing a coupling arrangement between the seatback carrier and rear seatback module according to another embodiment;

FIG. 7B is a cross-sectional top plan view of the coupling arrangement shown in FIG. 7B;

FIG. 7C is a cross-sectional top plan view of the coupling arrangement shown in FIG. 7B, showing an airbag in a deployed condition;

FIG. 8 is a perspective view of a molded-in retention clip disposed on a rear seatback module according to another embodiment of the present invention;

FIG. 9 is a perspective view of a molded-in retention pin disposed on a seatback carrier according to another embodiment of the present invention;

FIG. 10A is a fragmentary cross-sectional view taken at line VIA of FIG. 5, showing a coupling arrangement between the seatback carrier and rear seatback module according to another embodiment;

FIG. 10B is a cross-sectional top plan view of the coupling arrangement shown in FIG. 10A; and

FIG. 10C is a cross-sectional top plan view of the coupling arrangement shown in FIG. 10B, showing an airbag in a deployed condition.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Referring now to FIG. 1, reference numeral 10 generally designates a vehicle seat assembly according to an embodiment of the present disclosure. The vehicle seat assembly 10 includes a seat module 12 and a seatback assembly 13 which is contemplated to be pivotally coupled to the seat module 12. The seatback assembly 13 includes a front seatback module 14 and a rear seatback module 16 which are coupled to one another and supported by a seatback frame 15 (FIG. 4), as further described below. A headrest module 18 is coupled to the seatback assembly 13 at an upper portion thereof. The seat module 12, as shown in FIG. 1, is operably coupled to a track assembly 20 having first and second rails 21, 22 and a lever 23 configured for moving the vehicle seat assembly 10 between fore and aft positions as indicated by arrow A. As further shown in FIG. 1, a user control module 24 is mounted to a trim component 28 and is contemplated to be used to adjust the vehicle seat assembly 10 with regards to position and comfort settings. A lever 25 is further coupled to trim component 28 and can be used to actuate pivotal movement of the seatback assembly 13 relative to the seat module 12. A cap 26 is further mounted to trim component 28 and covers the pivotal mounting location of the seatback assembly 13 to the seat module 12. As further shown in FIG. 1, a seatbelt buckle receptacle 27 is also mounted to the seat module 12 and a front trim component 29 is disposed on a forward most portion of the seat module 12, such that the trim component 28 and trim component 29 cover a seat frame used to support the seat module 12.

As further shown in FIG. 1, the vehicle seat assembly 10 includes an airbag module 19 which, as further described below, is coupled to the seatback frame 15 (FIG. 4) in assembly. The airbag module 19, as shown in FIG. 1, is a deployable side-impact airbag (SAB) module configured to deploy an airbag when a collision event is sensed by a vehicle controller. The sensing capabilities of the vehicle controller are carried out in a manner generally known by one of ordinary skill in the art. The vehicle seat assembly 10 shown in FIG. 1 is contemplated to be a driver's side seat assembly, but may also be used on a passenger's side, in a mid-row location, in a rear seat location, or in third row option within a vehicle, wherein the location of the airbag module 19 may change accordingly. As generally understood in the art, a side-impact airbag module is generally positioned on a vehicle seat adjacent to a body component of the vehicle, such as a door or window, for outward deployment

Referring now to FIG. 2, a seatback carrier 30 is shown having first and second side members 32, 34 which are generally spaced apart and interconnected by upper and lower cross-members 36, 38. As shown in FIG. 2, the side members 32, 34 and upper and lower cross-members 36, 38 generally frame a central aperture 40 in assembly. The seatback carrier 30 is contemplated to be a composite part which is comprised of a polymeric or injection molded material, such that the seatback carrier 30 is a unitary part as shown in FIG. 2. The seatback carrier 30 is a component part of the front seatback assembly 14 shown in FIG. 1, and further described below. The first and second side members 32, 34 generally include outermost edges 32A, 34A, respectively. The outermost edges 32A, 34A generally define side perimeters of the seatback carrier 30, and also form a portion of a mating joint feature as further described below. The first and second side members 32, 34 further include a plurality of mounting members 32B, 34B, respectively, which are generally disposed adjacent to the outer edges 32A, 34A along a periphery of the seatback carrier 30, as shown in FIG. 2. The mounting members 32B, 34B of the first and second side members 32, 34 are configured to couple the seatback carrier 30 to the rear seatback module 16 (FIG. 1), as further described below. It is contemplated that the mounting members 32B, 34B may include a variety of configurations for accommodating various coupling arrangements between the seatback carrier 30 and the rear seatback module 16. As further shown in FIG. 2, inner mounting structures 42, 44 are disposed on inner portions of the first and second side members 32, 34 and may be used to couple the seatback carrier 30 to the seatback frame 15 (FIG. 4), or other like structure. With reference to the upper cross member 36, receiving apertures 36A, 36B are disposed thereon, and configured to receive support structures for the headrest assembly 18, as further described below.

Referring now to FIG. 3A, the front seatback module 14 is shown in an exploded view and includes an upholstered cover 50 and a support cushion 52 which are both contoured components having reciprocal configurations, such that the upholstered cover 50 covers the support cushion 52 in assembly. The upholstered cover 50 is contemplated to be comprised of a fabric, vinyl or leather material, or other like covering material (or combination thereof), while the support cushion 52 is contemplated to be comprised of a resilient foam material which may include areas of varying density or rigidity. In assembly, the upholstered cover 50 and support cushion 52 are further coupled to and supported by the seatback carrier 30. A lumbar support mechanism 54 is also shown in FIG. 3A which is contemplated to be coupled to and controlled by user control module 24 (FIG. 1) via a motor 56 and a cable 58 which is housed in a cable housing 60. In assembly, the lumbar support mechanism 54 is generally mounted in aperture 40 of the seatback carrier 30.

Referring now to FIG. 3B, the front seatback module 14 is shown in an assembled condition, wherein the components described above with reference to FIG. 3A are coupled together to form the front seatback module 14. Specifically, the upholstered cover 50 is shown covering the support cushion 52, which is then coupled to and supported by the seatback carrier 30.

Referring now to FIG. 4, the headrest module 18 is shown exploded away from the component parts of the seatback assembly 13. The headrest module 18 includes a head restraint 70 having first and second support posts 72, 74 extending downwardly therefrom. The first and second support posts 72, 74 include sleeves 76, 78 in which the first and second support posts 72, 74 are slideably received. The sleeves 76, 78 further include head portions 80, 82, respectively, which are configured to fit into mounting apertures 92, 94 disposed on a guide member 90. The guide member 90 includes first and second guide channels 96, 98 through which sleeves 76, 78 are received. The first and second guide channels 96, 98 disposed in the guide member 90 define anchor holes to which the first and second support posts 72, 74 are operably coupled in assembly. In assembly, the head restraint 70 is mounted to the guide member 90 by having the first and second support posts 72, 74 received in sleeves 76, 78 which are further received in the first and second guide channels 96, 98 of the guide member 90. With the head restraint 70 mounted in the guide member 90, the headrest module 18 provides a robust head restraint execution that is easy to assembly while providing both comfort and safety features.

As further shown in FIG. 4, the seatback frame 15 generally includes first and second side members 100, 102 which are spaced-apart and interconnected by an upper cross member 104 and a lower cross member 106. The first and second side members 100, 102 and upper and lower cross members 104, 106 generally frame a central aperture 108. In this way, the seatback frame 15 has a configuration similar to the seatback carrier 30. The first and second side members 100, 102 include laterally extending recessed portions 100A, 102A which are indentations configured to house the airbag module 19 in assembly. For purposes of this disclosure, the airbag module 19 is shown throughout as being disposed on the second side member 102 of the seatback frame 15. However, it is contemplated that the airbag module 19 can be disposed on the first side member 100 of the seatback frame 15, such that the vehicle seat assembly 10 (FIG. 1) can be configured for use as a driver's side or passenger's side assembly. The upper cross member 104 of the seatback frame includes mounting apertures 110, 112 which align with the receiving apertures 36A, 36B of the seatback carrier 30 to receive the first and second guide channels 96, 98 of the guide member 90 or the first and second support posts 72, 74 of the head restraint 70 in assembly. The seatback frame 15 is contemplated to be a reinforced metal seatback frame for providing sufficient support for a vehicle occupant in use. The seatback frame 15 further provides structural support for the attachment of the front seatback module 14 and rear seatback module 16 in assembly.

Referring again to FIG. 4, the rear seatback module 16 is shown as an outer shell 120, which generally includes first and second side members 122, 124 which are spaced-apart and interconnected by upper and lower cross members 126, 128. A lumbar support member 130 is disposed between the first and second side members 122, 124 and upper and lower cross members 126, 128. With the first and second side members 122, 124 and upper and lower cross members, the outer shell 120 has a similar configuration to the seatback carrier 30 and seatback frame 15 for coupling thereto. The outer shell 120 of the rear seatback module 16 further includes outermost edges 124A, 124B and a plurality of mounting features 122B, 124B which are used to couple the rear seatback module 16 to the front seatback module 14 around the seatback frame 15 in assembly. Specifically, the mounting features 122B, 124B are used in conjunction with a coupling arrangement, described below, to mount the rear seatback module 16 to the seatback carrier 30 of the front seatback module 14. The mounting features 122B, 124B are generally disposed on the first and second side members 122, 124 of the outer shell 120 along a perimeter thereof. In this way, mounting features 122B, 124B align with the mounting members 32B, 34B of the seatback carrier 30 for coupling thereto. The outer shell 120 is contemplated to be an injection molded polymeric part, providing the structural rigidity necessary for the seatback assembly 13 as assembled in FIG. 1.

Referring now to FIG. 5, the outer shell 120 and seatback carrier 30 are coupled together around the seatback frame 15. As noted above, the mounting members 32B and 34B of the seatback carrier 30 are configured to align with the mounting features 122B, 124B of the outer shell 120. In the configuration shown in FIG. 5, it is contemplated that the mounting members 32B, 34B of the seatback carrier 30 and the mounting features 122B, 124B of the outer shell 120 are in fact aligned, such that the seatback carrier 30 and outer shell 120 are coupled to one another using a coupling arrangement at the location of the mounting members 32B, 34B and mounting features 122B, 124B. As further shown in FIG. 5, the receiving apertures 36A, 36B of the upper cross member 36 of seatback carrier 30 are aligned with the mounting apertures 110, 112 of the seatback frame 15 for receiving and supporting the headrest module 18 (FIG. 4). The outer edge 32A of first side member 32, as well as the outer edge 34A of second side member 34 align with the outer edges 122A, 124A, respectively, of the outer shell 120 to define first and second seams or mating joints J1, J2. In this way, the outer edges 32A, 34A of the seatback carrier 30 and the outer edges 122A, 124A of the outer shell 120 form component parts of mating joint features at first and second mating joints J1, J2. The first and second joints J1, J2 define seams which are configured to expand to form a peripheral gap therealong due to a release of the various coupling arrangements used in conjunction with the mounting members 32B, 34B and mounting features 122B, 124B between the seatback carrier 30 and the outer shell 120. The various embodiments for the coupling arrangements between the seatback carrier 30 and outer shell 120 will now be described.

Referring now to FIGS. 6A and 6B, a cross-sectional view of the seatback carrier 30 and outer shell 120 is shown, wherein the seatback carrier 30 is coupled to the outer shell 120 via a coupling arrangement 130A around the seatback frame 15. In the embodiment shown in FIGS. 6A and 6B, the coupling arrangement 130A is located at a mounting member 34B1 of second side member 34 of the seatback carrier 30 and mounting feature 124B1 disposed on second side member 124 of the outer shell 120. It will be understood by one of ordinary skill that the mounting member 34B1 shown in FIGS. 6A and 6B is an exemplary embodiment of the plurality of mounting members 32B, 34B disposed along the periphery of the seatback carrier 30 (FIG. 2), and that mounting feature 124B1 is an exemplary embodiment of the mounting features 122B, 124B disposed along the periphery of the outer shell 120 as shown in FIG. 4. The embodiment of the coupling arrangement 130A may be utilized at all the locations where mounting members 32B, 34B align with mounting features 122B, 124B as described above with reference to FIG. 5. Further, it is contemplated that the coupling arrangement 130A may also be utilized only at the mounting members 32B, 34B and mounting features 122B, 124B that are disposed adjacent to an airbag module 19, as shown in FIG. 6B. As further described below, the coupling arrangement 130A is a releasable coupling arrangement that allows for the deployment of the airbag module 19 through mating joint J2. As such, the releasable coupling arrangement 130A need only be present adjacent an airbag module, such as airbag module 19. For ease of assembly, it is contemplated that the coupling arrangement 130A may be located throughout the seatback assembly 13 (FIG. 1), but is not necessarily so.

As shown in FIGS. 6A, 6B, the mounting member 34B1 is a substantially planar tab having a distal end 132. As best shown in FIG. 6B, mounting feature 124B1 of the second side member 124 of outer shell 120 is defined first and second mounting fins 134, 136 which are spaced-part from one another and which further extend inwardly from second side member 124 into a cavity 150. A clip member 140 is shown having a first arm 142 coupled to mounting member 34B1 at distal end 132 and a second arm 144 coupled to the first mounting fin 134, such that the second arm 144 is disposed between the first and second mounting fins 134, 136 in assembly. In this way, the coupling arrangement 130A couples the seatback carrier 30 to the outer shell 120 at mounting member 34B1 of the seatback carrier 30 and mounting feature 124B1 of the outer shell 120 using the clip member 140.

As further shown in FIGS. 6A and 6B, the second side 124 of outer shell 120 includes a first portion 124C and a second portion 124D. In assembly, the first portion 124C faces a car-rearward direction, while the second portion 124D faces a peripheral side of the vehicle as positioned therein. The second side 124 of outer shell 120 is spaced-apart from the second side 102 of the seatback frame 15 to define cavity 150 therebetween. As best shown in FIG. 6B, the airbag module 19 is mounted to the second side 102 of the seatback frame 15 within cavity 150 and is substantially concealed by second side 124 of the outer shell 120.

With specific reference to FIG. 6A, a mounting aperture 152 is shown disposed on the second side 102 of seatback frame 15 at recessed portion 102A. More specifically, the recessed portion 102A of second side member 102 of seatback frame 15 is shaped to retain the airbag module 19 (FIG. 6B) at mounting aperture 152 (FIG. 6A). As shown in FIG. 6B, a support member 160 of the airbag module 19 is mounted to the recessed portion 102A of second side member 102 of seatback frame 15 within cavity 150 at mounting aperture 152, via fastener 162. The support member 160, as shown in FIG. 6B, houses an electrical lead 164 that extends from the airbag module 19 through mounting aperture 152 to electrically couple the airbag module 19 with a vehicle controller 166, which may be disposed in a remote location within a vehicle interior, such as a vehicle instrument panel. It is contemplated that the vehicle controller 166 actuates the deployment of an airbag 170 (FIGS. 6B and 6C) from the airbag module 19 to inflate the airbag 170 from a contained position C (FIG. 6B) to a deployed position D (FIG. 6C) when the vehicle controller 166 senses a collision event.

Referring again to FIG. 6B, the airbag module 19 is shown having the airbag 170 in the contained position C. When a collision event is sensed by the vehicle controller 166, the airbag module 19 is configured to deploy the airbag 170 from the contained position C (FIG. 6B) to the deployed position D (FIG. 6C). To allow the airbag 170 to deploy, it is contemplated that the second side member 124 of outer shell 120 is flexibly resilient along first and second portions 124C, 124D. It is further contemplated that the second side member 34 of the seatback carrier 30 is also flexibly resilient, to allow for the release of the coupling arrangement 130A. With one or both of the second side members 34, 124 being flexibly resilient, a deployment force imparted by the airbag 170 of airbag module 19 can flex either one of the second side members 34, 124 to form a peripheral gap 172 at mating joint J2 through which the airbag 170 can deploy.

As further illustrated in FIG. 6C, the airbag 170 is deployed from airbag module 19 in a car-forward and outward direction through the seam or mating joint J2 by acting on the coupling arrangement 130A of the clip member 140 and mounting member 34B1 and first and second mounting fins 134, 136, thereby moving one or both of the outer edge 34A of the second side member 34 of the seatback carrier 30 away from the outer edge 124A of second side member 124 of the outer shell 120. This movement causes the coupling arrangement 130A of the clip member 140 and mounting member 34B1 and first and second mounting fins 134, 136 to release, thereby forming the peripheral gap 172 at mating joint J2. More specifically, as the airbag 170 deploys from the contained position C (FIG. 6B) to the deployed position D (FIG. 6C), the pressure realized from the deployment of the airbag 170 imparts a force Fl (FIG. 6B) that causes the coupling arrangement 130A of the clip member 140 and mounting member 34B1 and first and second mounting fins 134, 136 to fail or release at a specific location disposed along cavity 150, thereby making the coupling arrangement 130A a releasable coupling arrangement. As noted above, cavity 150 is defined between the second side member 124 of the outer shell 120 and second side member 102 of the seatback frame 15.

As shown in FIG. 6C, in the deployed position D, the airbag 170 inflates and extends from the support member 160 outward and forward through the mating joint J2 at peripheral gap 172 formed between outer edges 34A, 124A and beyond the second side 124 of the outer shell 120. In this deployed position D, the airbag 170 provides a cushioned support between a seated passenger and an outboard interior surface of the vehicle, such as the side door or window. Upon inflation of the airbag 170, the airbag 170 deforms the second portion 124D of the second side 124 of the outer shell 120 laterally outward. Also, the deploying force of the airbag 170 may deform the second side 34 of the seatback carrier 30 forward, such that the mating joint J2 widens to define peripheral gap 172 at a consistent rate and orientation to accurately direct the airbag 170 forward beyond the second side 124 of the outer shell 120 with minimal resistance from the second side 124 of the outer shell 120. When the mating joint J2 widens to define peripheral gap 172, the coupling arrangement 130A is released. The deployed position D of the airbag 170, as shown in FIG. 6C, is merely one depiction of an incremental stage of deployment as the airbag 170 inflates at a rapid rate pushing the airbag 170 out from the support member 160 of the airbag module 19 in the outward and forward direction beyond the illustrated position. It is contemplated that the airbag 170 may inflate using gases generated from a pyrotechnic reaction, a compressed air release, and/or another chemical reaction or other conceivable inflation methods. It is also conceivable that after deployment of the airbag module 19, the airbag module 19 may be replaced and the seatback assembly 13 may be restored with minimal necessary repair.

Referring now to FIGS. 7A and 7B, a cross-sectional view of the seatback carrier 30 and outer shell 120 is shown, wherein the seatback carrier 30 is coupled to the outer shell 120 via another embodiment of a releasable coupling arrangement 130B around the seatback frame 15. In the embodiment shown in FIGS. 7A and 7B, the coupling arrangement 130B is located at mounting member 34B2 of second side member 34 of the seatback carrier 30 and mounting feature 124B2 disposed on second side member 124 of the outer shell 120. It will be understood by one of ordinary skill that the mounting member 34B2 shown in FIGS. 7A and 7B is exemplary of the plurality of mounting members 32B, 34B disposed around the periphery of seatback carrier 30 (FIG. 2), and that mounting feature 124B2 is exemplary of the plurality of mounting features 122B, 124B disposed around the periphery of the outer shell 120 as shown in FIG. 4. Like the releasable coupling arrangement 130A shown in FIGS. 6A-6C, the releasable coupling arrangement 130B may be utilized at all the locations where mounting members 32B, 34B align with mounting features 122B, 124B as described above with reference to FIG. 5, or only at locations of the seatback assembly 13 (FIG. 1) adjacent an airbag module, such as airbag module 19.

As shown in FIGS. 7A, 7B, the mounting member 34B2 is a substantially planar tab having a mounting aperture 34D disposed therethrough. Similarly, as best shown in FIG. 7B, mounting feature 124B2 of the second side member 124 of outer shell 120 includes a substantially planar tab having a mounting aperture 124E disposed therethrough. In assembly, the mounting aperture 34D of mounting member 34B2 is configured to align with mounting aperture 124E of mounting feature 124B2. A pin member 180 is shown having an expandable body portion 182 with spring members 182A and 182B. The pin member 180 further includes a first neck portion 184, an abutment portion 186, a second neck portion 188 and a head portion 190. The pin member 180 is inserted through the mounting aperture 124E of mounting feature 124B2 and further inserted through the mounting aperture 34D of mounting member 34B2 in assembly. As best shown in FIG. 7B, with the pin member 180 fully inserted, the first neck portion 184 is disposed in mounting aperture 34D of mounting member 34B2, and the second neck portion 188 is disposed in mounting aperture 124E of mounting feature 124B2. The abutment portion 186 abuts mounting member 34B2 and further abuts mounting feature 124B2 in assembly, as shown in FIG. 7B. As noted above, when a collision event is sensed by the vehicle controller 166, the airbag module 19 is configured to deploy the airbag 170 from the contained position C (FIG. 7B) to the deployed position D (FIG. 7C).

Referring now to FIG. 7C, the airbag 170 is deployed from airbag module 19 in a forward direction through the seam or mating joint J2 by acting on the coupling arrangement 130B of the pin member 180 and mounting member 34B2 and mounting feature 124B2, thereby moving one or both of the outer edge 34A of the second side member 34 of the seatback carrier 30 away from the outer edge 124A of second side member 124 of the outer shell 120. This movement causes the coupling arrangement 130B to release, thereby forming the peripheral gap 172 at mating joint J2. Thus, in a manner similar to that described above with reference to FIG. 6C, the coupling arrangement 130B releases under the pressure of the airbag 170, thereby making the coupling arrangement 130B a releasable coupling arrangement. The coupling arrangement 130B can be released by the pin member 180 being pulled from either mounting aperture 34D or 124E, so long as the peripheral gap 172 is formed and the airbag 170 can fully deploy.

Referring now to FIG. 8, a portion of first side member 122 of the outer shell 120 is shown having mounting feature 122B1 disposed thereon. The mounting feature 122B1 is shown in the form of a molded-in retention clip 200 having a base portion 201 extending inwardly from the first side member 122 of the outer shell 120. As used herein, the term “molded-in” means that the subject part is cast or molded as a unitary part of the seatback carrier 30 or outer shell 120. A C-shaped mounting aperture 202 is formed in the base portion 201 at a distal end thereof, and includes a boss 204 extending outwardly therefrom. A relief portion 208, is defined at the distal most end of the C-shaped mounting aperture 202 and allows the C-shaped mounting aperture 202 to flex as needed for coupling and uncoupling the outer shell 120 to a corresponding seatback carrier 30, as further described below with reference to FIGS. 10A-10C.

Referring now to FIG. 9, a portion of first side member 32 of the seatback carrier 30 is shown having mounting member 32B1 disposed thereon. The mounting member 32B1 is shown in the form of a molded-in retention pin 220 having a base portion 221 with a body portion 222 of the retention pin 220 extending in a car-rearward direction from the first side member 32 of the seatback carrier 30. The body portion 222 of the retention pin 220 is in the form of a column or hollow cylinder which includes a relief portion 224 in which a flexibly resilient spring finger 226 is disposed. The spring finger 226 includes a ramped abutment member 228 which is configured to abut a rear side 206 of the C-shaped mounting aperture 202 of the molded-in retention clip 200 of the outer shell 120 in assembly. The retention pin 220 further includes a mounting tab 230 extending outwardly from the body portion 222 which is further coupled to a reinforcement tab 232 disposed on the first side member 32 of the seatback carrier 30. In assembly, the body portion 222 of the retention pin 220 is received in the C-shaped mounting aperture 202 of the molded-in retention clip 200 of the outer shell 120. The flexibly resilient spring finger 226 is configured to flex as the body portion 222 of the retention pin 220 is received in the C-shaped mounting aperture 202 and is further configured to spring back into place when the ramped abutment member 228 clears the rear side 206 of the C-shaped aperture 202 of the molded-in retention clip 200. When the molded-in retention clip 200 and molded-in retention pin 220 are coupled together (FIG. 10A), the mounting tab 230 of the molded-in retention pin 220 is received through the relief portion 208 of the molded-in retention clip 200 of the outer shell 120.

Referring now to FIGS. 10A and 10B, a cross-sectional view of the seatback carrier 30 and outer shell 120 is shown, wherein the seatback carrier 30 is coupled to the outer shell 120 via another embodiment of a releasable coupling arrangement 130C around the seatback frame 15. In the embodiment shown in FIGS. 10A and 10B, the coupling arrangement 130C is located at mounting member 34B3 of the second side member 34 of the seatback carrier 30 and mounting feature 124B3 of the second side member 124 of the outer shell 120. It will be understood by one of ordinary skill that the mounting member 34B3 shown in FIGS. 10A and 10B is a corresponding mounting member to mounting member 32B1 shown in FIG. 9 and is further exemplary of the plurality of mounting members 32B, 34B disposed around the periphery of seatback carrier 30 (FIG. 2). Similarly, mounting feature 124B3 is a corresponding mounting feature to mounting feature 122B1 shown in FIG. 8, and is further exemplary of the plurality of mounting features 122B, 124B disposed around the periphery of the outer shell 120 as shown in FIG. 4. Like the releasable coupling arrangements 130A, 130B shown in FIGS. 6A-6C and 7A-7C, the releasable coupling arrangement 130C may be utilized at all the locations where mounting members 32B, 34B align with mounting features 122B, 124B as described above with reference to FIG. 5, or only at locations of the seatback assembly 13 (FIG. 1) adjacent an airbag module, such as airbag module 19.

As described above, and shown in FIGS. 10A, 10B, the mounting member 34B3 defines a molded-in retention pin 220. Further, mounting feature 124B3 of the second side member 124 of outer shell 120 defines a molded-in retention clip 200. The molded-in retention pin 220 of the seatback carrier 30 is received in the molded-in retention clip 200 of the outer shell 120 to define the releasable coupling arrangement 130C. The molded-in retention pin 220 of the seatback carrier 30 is fully received in the molded-in retention clip 200 of the outer shell 120 when the abutment member 228 of spring finger 226 clears the C-shaped aperture 202 of the molded-in retention clip 200 as shown in FIGS. 10A and 10B. In a similar manner as noted above, when a collision event is sensed by the vehicle controller 166, the airbag module 19 is configured to deploy the airbag 170 from the contained position C (FIG. 10B) to the deployed position D (FIG. 10C).

Referring now to FIG. 10C, the airbag 170 is deployed from airbag module 19 in a forward direction through the seam or mating joint J2 by acting on the releasable coupling arrangement 130C of the molded-in retention pin 220 of the seatback carrier 30 and the molded-in retention clip 200 of the outer shell 120, thereby moving one or both of the outer edge 34A of the second side member 34 of the seatback carrier 30 away from the outer edge 124A of second side member 124 of the outer shell 120. This movement causes the releasable coupling arrangement 130C to release, thereby forming the peripheral gap 172 at mating joint J2. Thus, in a manner similar to that described above with reference to FIGS. 6C and 7C, the releasable coupling arrangement 130C releases under the pressure of the airbag 170, thereby making the coupling arrangement 130C a releasable coupling arrangement. The coupling arrangement 130C can be released by the molded-in retention pin 220 of the seatback carrier 30 being pulled from the C-shaped aperture 202 of the molded-in retention clip 200 of the outer shell 120, thereby expanding the peripheral gap 172 such that the airbag 170 can fully deploy.

Thus, the releasable coupling arrangements 130A, 130B and 130C described above can take different forms, so long as the coupling arrangements 130A, 130B and 130C are capable of coupling the outer shell 120 to the seatback carrier 30, while still being releasable under the force of an airbag, such as airbag 170 of airbag module 19, to allow for proper and full deployment of the airbag 170 through the peripheral gap 172 formed between the outer shell 120 and the seatback carrier 30.

It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. 

What is claimed is:
 1. A rear seatback module, comprising: an outer shell having first and second side members with one or more mounting features disposed along a length of the first and second side members, wherein each of the one or more mounting features includes a planar tab having a mounting aperture disposed therethrough; a seatback carrier having first and second side members with one or more mounting members disposed along a length of the first and second side members, wherein the one or more mounting members disposed on the seatback carrier are configured to align with the one or more mounting features disposed on the outer shell in assembly; a releasable coupling arrangement defined between the one or more mounting features disposed on the outer shell and the one or more mounting members disposed on the seatback carrier; a seatback frame disposed between the outer shell and the seatback carrier; and an airbag module coupled to the seatback frame, wherein the releasable coupling arrangement is configured to release upon deployment of the airbag module to disengage a portion of the outer shell from the seatback carrier along a mating joint formed therebetween.
 2. The rear seatback module of claim 1, wherein the one or more mounting members of the first and second side members of the seatback carrier define substantially planar mounting tabs having mounting apertures disposed therethrough.
 3. The rear seatback module of claim 2, including: one or more pin members having a neck portion and a body portion, wherein the one or more pin members are received through the mounting apertures of the outer shell and further received through the mounting apertures of the seatback carrier.
 4. The rear seatback module of claim 3, wherein the neck portion of the one or more pin members includes first and second neck portions, the first neck portion disposed in the mounting apertures of the seatback carrier, and the second neck portion disposed in the mounting apertures of the outer shell.
 5. The rear seatback module of claim 4, wherein the body portions of the one or more pin members further include outwardly extending flexibly resilient spring members.
 6. The rear seatback module of claim 5, wherein the one or more pin members further include abutment portions disposed between the first and second neck portions, the abutment portion abutting the planar mounting tabs of the mounting features and mounting members in assembly.
 7. The rear seatback module of claim 6, wherein the one or more pin members further include head portions disposed adjacent to the second neck portions, the head portion abutting the planar mounting tabs of the mounting features of the outer shell in assembly.
 8. The rear seatback module of claim 1, wherein the first and second side members of the outer shell are flexibly resilient.
 9. The rear seatback module of claim 8, wherein the first and second side members of the seatback carrier are flexibly resilient.
 10. The rear seatback module of claim 1, wherein the airbag module is a side-impact airbag module.
 11. A rear seatback module, comprising: an outer shell releasably engaged with a seatback carrier via a coupling arrangement to define a mating joint therebetween, wherein the outer shell further includes first and second side members having a plurality of molded-in retention clips disposed thereon, and further wherein the seatback carrier includes first and second side members having a plurality of molded-in retention pins disposed thereon, wherein the molded-in retention pins includes hollow cylinder-shaped body portions with a flexibly resilient spring finger disposed in a relief portion thereof, and further wherein the molded-in retention pins are releasably received the molded-in retention clips; a seatback frame disposed between the seatback carrier and the outer shell; and an airbag module coupled to the seatback frame, wherein the coupling arrangement is configured to release upon deployment of the airbag module to disengage a portion of the outer shell from the seatback carrier along the mating joint.
 12. A rear seatback module, comprising: an outer shell coupled to a seatback carrier via a releasable coupling arrangement, wherein the outer shells further includes a plurality of molded-in retention clips, and further wherein the seatback carrier includes a plurality of molded-in retention pins disposed thereon, wherein the molded-in retention pins includes hollow cylinder-shaped body portions with a relief portions, and further wherein the molded-in retention pins are releasably received the molded-in retention clips; a seatback frame disposed between the seatback carrier and the outer shell; and an airbag module coupled to the seatback frame, wherein the releasable coupling arrangement is configured to release upon deployment of an airbag from the airbag module to define a peripheral gap between the outer shell and seatback carrier through which the airbag is deployed.
 13. The rear seatback module of claim 12, wherein the airbag module is substantially concealed by the outer shell.
 14. The rear seatback module of claim 13, wherein the outer shell further includes first and second side members upon which the plurality molded-in retention clips are disposed, and further wherein the seatback carrier includes first and second side members upon which the plurality molded-in retention pins are disposed.
 15. The rear seatback module of claim 14, wherein the first and second side members of the outer shell are flexibly resilient.
 16. The rear seatback module of claim 15, wherein the first and second side members of the outer shell are configured to flex under a force imparted by the deployment of the airbag module to release the releasable coupling arrangement and widen the peripheral gap.
 17. The rear seatback module of claim 12, wherein each of the molded-in retention pins of the plurality of retention pins includes a flexibly resilient spring finger disposed in the relief portion thereof.
 18. The rear seatback module of claim 17, wherein the molded-in retention clips include a C-shaped mounting aperture configured to receive the body portion and spring finger of the molded-in retention pins to define the releasable coupling arrangement. 